Nozzle Reactor Systems and Methods of Use

ABSTRACT

A nozzle reactor system for increasing the conversion rate of material feed injected into the nozzle reactor system. The system includes two or more nozzle reactors aligned in parallel. A main stream of material to be upgraded is divided such that one stream is produced for each nozzle reactor in the system. Each nozzle reactor includes an interior reactor chamber and an injection passage and material feed passage that are each in material injecting communication with the interior reactor chamber. Furthermore, the injection passage is aligned transversely to the injection passage. The injection passage is configured to accelerate cracking material passed therethrough to a supersonic speed. The product produced from each of the nozzle reactors is combined into one product stream.

This application claims priority to U.S. Provisional Patent ApplicationNo. 61/553,009, filed Oct. 28, 2011, the entirety of which is herebyincorporated by reference.

BACKGROUND

Nozzle reactors have long been used to cause materials to interact andachieve alteration of the mechanical or chemical composition of thematerials. Typically, this involves injecting differing types ofmaterials into a reactor chamber of a nozzle reactor and allowing thematerials to interact.

One example of a nozzle reactor disclosure is Canadian PatentApplication No. 2,224,615 (the '615 Publication). This reference statesthat its disclosed nozzle reactor is designed to receive a bitumen/steamflow mixture into a single central nozzle reactor passage extendingalong the axial length of the nozzle reactor. The reference states thatthe nozzle forms a flow passageway of circular diametric cross-sectionhaving the following sections in sequence from the bitumen/steam flowmixture inlet: a first contraction section of reducing diameter foraccelerating the flow and reducing the size of bitumen droplets; adiffuser section of expanding diameter to decelerate the flow and inducea shock wave; a second contraction section to accelerate the mixturemore than the first contraction section; and an orifice outlet forproducing an output jet or spray. The '615 Publication further statesthat the disclosed nozzle reactor reduces bitumen droplet size fromabout 12,000 μm to about 300 μm.

Among other things, the nozzle reactor of the '615 Publication receivesa pre-mixed bitumen/steam liquid medium. As a result, the nozzle reactortechnique of the '615 Publication requires implementation of one or moresubstantial pre-mixing steps in order to generate and deliver thedesired bitumen/steam liquid medium to the central nozzle reactorpassage. In addition, the pre-mixed liquid medium (including bitumen inthe mixture) inherently yields limited velocities of the medium throughthe nozzle reactor.

Another example of a nozzle reactor is described in U.S. PatentApplication Publication No. 2004/0065589 (the '589 Publication). Thenozzle reactor discussed in the '589 Publication has two steam injectorsdisposed: (i) laterally separated from opposing sides of a central,axially extending vapor expansion feed stock injector, (ii) at an acuteangle to the axis of the central vapor expansion feed stock injector.The steam injectors are thus disposed for ejection from the steaminjectors in the direction of travel of material feed stock injected bythe feed stock injector. Each of the three injectors has a discharge endfeeding into a central reactor ring or tube extending coaxially from thecentral feed stock injector. As shown in the '589 Publication, thecentral feed stock injector appears as if it may have adivergent-to-convergent axial cross-section with a nearly pluggedconvergent end; but as shown in related Canadian Patent Application No,2,346,181 (the '181 Publication), the central feed stock injector has astraight-through bore. As the '589 Publication explains, superheatedsteam is injected through the two laterally opposed steam injectors intothe interior of reactor tube in order to impact a pre-heated,centrally-located feed stream of certain types of heavy hydrocarbonsimultaneously injected through the vapor expansion feed stock injectorinto the interior of the reactor tube. The '589 Publication states thatthe object of '589 nozzle reactor is to crack the feed stream intolighter hydrocarbons through the impact of the steam feeds with theheavy hydrocarbon feed within the reactor tube. According to the '589Publication, the types of heavy hydrocarbons processed with the '589nozzle reactor are crude oil, atmospheric residue, and heavydistillates. With the nozzle reactors of either the '589 Publication andthe '181 Publication, a central oil feed stock jet intersects the steamjets at some distance from the ejection of these jets from theirrespective injectors.

The applicants have discovered that, among other things, nozzle reactorsof the type shown in the '589 Publication, the '181 Publication andassociated methods of use: (i) are inefficient; (ii) typically andperhaps always provide only sonic or subsonic velocity of a feed stockinto the associated reactor tube; and (iii) yield excessive un-crackedor insufficiently cracked heavy hydrocarbons. These same nozzle reactorsalso typically yield excessive coke formation and scaling of the nozzlereactor walls, reducing the efficiency of the nozzle reactor andrequiring substantial effort to remove the scale formation within thenozzle reactor.

SUMMARY

Disclosed below are representative embodiments that are not intended tobe limiting in any way. Instead, the present disclosure is directedtoward features, aspects, and equivalents of the embodiments of thenozzle reactor and method of use described below. The disclosed featuresand aspects of the embodiments can be used alone or in variouscombinations and sub-combinations with one another.

Generally, a nozzle reactor having a variety of aspects and methods ofuse are described herein. In certain embodiments, the nozzle reactorprovides a hydrocarbon cracking nozzle reactor. In certain embodiments,the method includes generating a supersonic stream of cracking materialand impacting hydrocarbon material with the supersonic stream ofcracking material.

In some embodiments of the nozzle reactor, the nozzle reactor has amaterial feed passage extending into an interior reactor chamber sectiongenerally transverse to the exit or injection axis of at least oneinjection passage. In some embodiments, at least one injection passageis coaxial with the axis of an associated interior reactor chamber andat least one material feed passage is disposed to inject material feedto impact the cracking material injected at the ejection end of theinjection passage.

In some embodiments, the nozzle reactor has an injection passageabutting an interior reactor chamber and a material feed passageextending into the interior reactor chamber transverse to the axis ofthe injection passage and adjacent the ejection end of the injectionpassage. The injection passage can be a non-linear injection passageinjectingly penetrating the interior reactor chamber.

In some embodiments, the injection passage can have a cross-sectionalconfiguration in which opposing side wall portions are curved inwardlytoward the central axis of the injection passage along the axial lengthof the injection passage. Preferably, the curved side wall portions ofthe injection passage has a smooth finish without sharp edges or suddenchanges in surface contour, most preferably along the entire axiallength of the injection passage. In some embodiments, the curved sidewall portions of the injection passage can provide a nearly orsubstantially isentropic or frictionless passage for cracking materialpassing through the injection passage into the interior reactor chamber.

In some embodiments, the nozzle reactor includes a material feed passagehaving at least one or more material feed ports, and if desired one ormore partially or completely annular material feed ports, injectinglyabutting the interior reactor chamber. In some embodiments, a materialfeed passage can include a reactor chamber material feed slotinjectingly penetrating at least a substantial portion, or if desired,the entire outer circumferential periphery of an annular material feedport. The latter configuration can, in the case of a completely annularmaterial feed port for example, provide impact of the material feedstream with the entire circumference of the injected cracking materialstream.

In sonic embodiments, the reactor chamber material feed slot or end ofthe annular material feed port is disposed axially adjacent the end ofthe injection passage injectingly penetrating the interior reactorchamber. In this fashion, material feed can be injected through thematerial feed passage radially inwardly toward, and optionallytransverse to, an adjacent cracking material injected through theinjection passage.

In some embodiments, the nozzle reactor comprises an annular or otherport insert member mounted intermediate the interior reactor chamber andthe injection passage. The ejection port of the interior reactorchamber, opposite the injection passage, can provide a passage throughwhich cracking material and other material can pass out of the reactorbody. The injection passage may have a frustoconical configuration.

Some embodiments of the present invention provide a conical, stepped, ortelescoped interior reactor chamber, or a combined conical and otherwiseshaped interior reactor chamber, extending along the axial length of theinterior reactor chamber. The interior reactor chamber can be configuredto generally provide interfering, turbulence-inducing contact,optionally limited contact, between the cracking material and thematerial feed injected into the interior reactor chamber.

In some embodiments, the injection passage includes an insert mountedwithin the injection passage and has a thin-thick-thin cross-sectionalong the axial length of the insert. The insert can have a radiallyoutwardly curved periphery along the axial length of the insert.

Some embodiments provide a method of injecting cracking material and afeed material into a nozzle reactor. Some embodiments can includeinjecting cracking material from an injection passage into an interiorreactor chamber along the axial length of the interior reactor chambersection and injecting feed material into the interior reactor chambertransverse to the axis of the interior reactor chamber. In someembodiments, the feed material is injected adjacent the end of theinjection passage injectingly abutting the interior reactor chamber. Asa result, the cracking material impacts the feed material virtuallyimmediately after ejection from the injection passage. This impact canthus take place before the velocity of the cracking material diminishesappreciably.

In some embodiments, cracking material comprises superheated steam andthe feed material comprises pre-heated heavy hydrocarbons. The heavyhydrocarbons can include or consist largely or even essentially ofbitumen. Cracking material also can include natural gas, carbon dioxide,or other gases.

In some embodiments, the feed material is injected to impact thecracking material upon its ejection from the injection passage, at anangle of about 90°.

In some embodiments, the bar pressure level of the superheated steamcracking material is substantially greater than, and preferably morethan double, the pressure level within the interior reactor chamber.

In some embodiments, the cracking material is injected through theinjection passage into the interior reactor chamber at supersonicspeeds. In some embodiments, the cracking material injection speed istwice the speed of sound or more.

Some embodiments provide reduced back flow and enhanced mechanical shearwithin the interior reactor chamber. Some embodiments may do so andaccomplish substantial cracking of a desired hydrocarbon very quicklyand generally without substantial regard to retention time of thematerial feeds within the reactor body. In other embodiments, increasedretention time of the material feed within the reactor body can resultin higher cracking rates.

Some embodiments of the apparatus and methods provide more efficientgeneration and transfer of kinetic energy from a cracking material to amaterial feed. Some embodiments also provide increased materialprocessing capability and output and reduced uncracked material or otherby-products in the output from the nozzle reactor or retained within theconfines of the nozzle reactor, such as reduced scale formation on theside walls of the interior reactor chamber. Some embodiments alsoprovide a relatively economical, durable, and easy-to-maintain or repairnozzle reactor.

Some embodiments provide mechanical cracking of heavy oils orasphaltenes. In certain of these embodiments, the cracking reaction canbe caused primarily mechanically by the application of extreme shearrather than by temperature, retention time, or interaction with acatalyst. In some embodiments, the cracking may be selective, such as byselectively cracking primarily only the larger molecules making upcertain heavy hydrocarbons in a hydrocarbon feed stock.

In some embodiments, the nozzle reactor provides not only more selectiveand efficient cracking of material feed but also, or alternatively,reduced coke formation and reactor chamber scaling. In some embodiments,reactor chamber scaling may even be eliminated.

In some embodiments, a nozzle reactor system is disclosed. The nozzlereactor system generally comprises a first nozzle reactor and a secondnozzle reactor. Each of the first nozzle reactor and the second nozzlereactor can be a nozzle reactor as described herein. The nozzle reactorsystem can also include a first separation unit. The first separationunit is in fluid communication with an ejection end of the first nozzlereactor such that material leaving the nozzle reactor flows into theseparation unit. The first separation unit includes a light streamoutlet and a heavy stream outlet. The heavy stream outlet is in fluidcommunication with the material feed passage of the second nozzlereactor such that the heavy stream is injected into the nozzle reactorfor further cracking.

In some embodiments, a feed material cracking method is disclosed. Themethod includes a step of injecting a first stream of cracking materialthrough an injection passage of a first nozzle reactor into an interiorreaction chamber of a first nozzle reactor The method further includes astep of injecting a material feed into the interior reactor chamber ofthe first nozzle reactor adjacent to the injection passage of the firstnozzle reactor and transverse to the first stream of cracking materialentering the interior reactor chamber of the first nozzle reactor fromthe injection passage of the first nozzle reactor to produce first lightmaterial and first heavy material. The method also includes a step ofinjecting a second stream of cracking material through an injectionpassage of a second nozzle reactor into a reaction chamber of a secondnozzle reactor. Finally, the method includes a step of injecting thefirst heavy material into the interior reactor chamber of the secondnozzle reactor adjacent to the injection passage of the second nozzlereactor and transverse to the second stream of cracking materialentering the interior reactor chamber of the second nozzle reactor fromthe injection passage of the second nozzle reactor to thereby producesecond light material and second heavy material.

In some embodiments, a nozzle reactor system comprises: a streamdividing apparatus comprising a first output port and a second outputport; a first nozzle reactor having a feed material injection port influid communication with the first output port of the stream dividingapparatus, and an ejection end; a second nozzle reactor having a feedmaterial injection port in fluid communication with the second outputport of the stream dividing apparatus, and an ejection end; and a mixingapparatus having a first input port in fluid communication with theejection end of the first nozzle reactor, and a second input port influid communication with the ejection end of the second nozzle reactor.

In some embodiments, a material cracking method comprises injecting afirst material stream into a stream dividing apparatus and producing afirst divided stream and a second divided stream, injecting the firstdivided stream into a first nozzle reactor and injecting the seconddivided stream into a second nozzle reactor, injecting a stream ofcracking material into the first nozzle reactor and injecting a streamof cracking material into the second nozzle reactor, and combining afirst nozzle reactor product from the first nozzle reactor and a secondnozzle reactor product from the second nozzle reactor in a mixingapparatus.

The foregoing and other features and advantages of the presentapplication will become more apparent from the following detaileddescription, which proceeds with reference to the accompanying figures.In this regard, it is to be understood that the scope of the inventionis to be determined by the claims as issued and not by whether givensubject includes any or all features or aspects noted in this Summary oraddresses any issues noted in the Background.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional, schematic view of one embodiment of anozzle reactor suitable for use in various embodiments of the methodsand systems described herein;

FIG. 2 is a cross-sectional view of the nozzle reactor of FIG. 1,showing further construction details for the nozzle reactor;

FIG. 3 shows a cross-sectional view of one embodiment of a nozzlereactor suitable for use in various embodiments of the systems andmethods described herein;

FIG. 4 shows a cross-sectional view of the top portion of the nozzlereactor shown in FIG. 3;

FIG. 5 shows a cross-sectional perspective view of the mixing chamber inthe nozzle reactor shown in FIG. 3;

FIG. 6 shows a cross-sectional perspective view of the distributor fromthe nozzle reactor shown in FIG. 3;

FIG. 7 shows a cross-sectional view of another embodiment of a nozzlereactor suitable for use in various embodiments of the systems andmethods described herein; and

FIG. 8 shows a cross-sectional view of the top portion of the nozzlereactor shown in FIG. 7.

FIG. 9 is a flow diagram illustrating a feed material cracking methodaccording to various embodiments disclosed herein;

FIG. 10 is a block diagram illustrating a nozzle reactor systemaccording to various embodiments disclosed herein;

FIG. 11 is a block diagram illustrating a nozzle reactor systemaccording to various embodiments described herein;

DETAILED DESCRIPTION

Before describing the details of the various embodiments herein, itshould be appreciated that the term “hydrocarbon” and “hydrocarbons” asused herein may include organic material besides hydrogen and carbon,such as vanadyl, sulfur, nitrogen, and any other organic compound thatmay be in oil.

With reference to FIG. 1, the nozzle reactor, indicated generally at 10,has a reactor body injection end 12, a reactor body 14 extending fromthe reactor body injection end 12, and an ejection port 13 in thereactor body 14 opposite its injection end 12. The reactor bodyinjection end 12 includes an injection passage 15 extending into theinterior reactor chamber 16 of the reactor body 14. The central axis Aof the injection passage 15 is coaxial with the central axis B of theinterior reactor chamber 16.

With continuing reference to FIG. 1, the injection passage 15 has acircular diametric cross-section and, as shown in the axially-extendingcross-sectional view of FIG. 1, opposing inwardly curved side wallportions 17, 19 (i.e., curved inwardly toward the central axis A of theinjection passage 15) extending along the axial length of the injectionpassage 15. In certain embodiments, the axially inwardly curved sidewall portions 17, 19 of the injection passage 15 allow for a higherspeed of injection gas when passing through the injection passage 15into the interior reactor chamber 16.

In certain embodiments, the side wall of the injection passage 15 canprovide one or more among: (i) uniform axial acceleration of crackingmaterial passing through the injection passage; (ii) minimal radialacceleration of such material; (iii) a smooth finish; (iv) absence ofsharp edges; and (v) absence of sudden or sharp changes in direction.The side wall configuration can render the injection passage 15substantially isentropic. These latter types of side wall and injectionpassage 15 features can be, among other things, particularly useful forpilot plant nozzle reactors of minimal size.

A material feed passage 18 extends from the exterior of the reactor body14 toward the interior reactor chamber 16 transversely to the axis 13 ofthe interior reactor chamber 16. The material feed passage 18 penetratesan annular material feed port 20 adjacent the interior reactor chamberwall 22 at the interior reactor chamber injection end 24 abutting thereactor body injection end 12. The material feed port 20 includes anannular, radially extending reactor chamber feed slot 26 inmaterial-injecting communication with the interior reactor chamber 16.The material feed port 20 is thus configured to inject feed material:(i) at about a 90° angle to the axis of travel of cracking materialinjected from the injection passage 15; (ii) around the entirecircumference of a cracking material injected through the injectionpassage 15; and (iii) to impact the entire circumference of the freecracking material stream virtually immediately upon its emission fromthe injection passage 15 into the interior reactor chamber 16.

The annular material feed port 20 may have a U-shaped or C-shapedcross-section among others. In certain embodiments, the annular materialfeed port 20 may be open to the interior reactor chamber 16, with noarms or barrier in the path of fluid flow from the material feed passage18 toward the interior reactor chamber 16. The junction of the annularmaterial feed port 20 and material feed passage 18 can have a radiusedcross-section.

In alternative embodiments, the material feed passage 18, annularmaterial feed port 20, and/or injection passage 15 may have differingorientations and configurations, and there can be more than one materialfeed port and associated structure. Similarly, in certain embodimentsthe injection passage 15 may be located on or in the interior reactorchamber side 23 (and if desired may include an annular cracking materialport) rather than at the reactor body injection end 12 of the reactorbody 14, and the annular material feed port 20 may be non-annular andlocated at the reactor body injection end 12 of the reactor body 14.

In the embodiment of FIG. 1, the interior reactor chamber 16 can bebounded by stepped, telescoping side walls 28, 30, 32 extending alongthe axial length of the reactor body 14. In certain embodiments, thestepped side walls 28, 30, 32 are configured to: (i) allow a free jet ofinjected cracking material, such as superheated steam, natural gas,carbon dioxide, or other gas, to travel generally along and within theconical jet path C generated by the injection passage 15 along the axisB of the interior reactor chamber 16, while (ii) reducing the size orinvolvement of back flow areas, e.g., 34, 36, outside the conical orexpanding jet path C, thereby forcing increased contact between the highspeed cracking material jet stream within the conical jet path C andfeed material, such as heavy hydrocarbons, injected through the annularmaterial feed port 20.

As indicated by the drawing gaps 38, 40 in the embodiment of FIG. 1, thereactor body 14 has an axial length (along axis B) that is much greaterthan its width. In the FIG. 1 embodiment, exemplary length-to-widthratios are typically in the range of 2 to 4 or more.

The dimensions of the various components of the nozzle reactor shown inFIG. 1 are not limited, and may generally be adjusted based on theamount of material feed to be cracked inside the nozzle reactor. Table 1provides exemplary dimensions for the various components of the nozzlereactor based on the hydrocarbon input in barrels per day (BPD).

TABLE 1 Material Feed Input (BPD) Nozzle Reactor Component (mm) 5,00010,000 20,000 Injection Passage, Enlarged Volume 148 207 295 InjectionSection Diameter Injection Passage, Reduced Volume 50 70 101 Mid-SectionDiameter Injection Passage, Enlarged Volume 105 147 210 Ejection SectionDiameter Injection Passage Length 600 840 1,200 Interior Reactor ChamberInjection End 187 262 375 Diameter Interior Reactor Chamber Ejection End1,231 1,435 1,821 Diameter Interior Reactor Chamber Length 6,400 7,1608,800 Overall Nozzle Reactor Length 7,000 8,000 10,000 Overall NozzleReactor Outside 1,300 1,600 2,000 Diameter

With reference now to FIG. 2 and the particular embodiment showntherein, the reactor body 44 includes a generally tubular centralsection 46 and a frustoconical ejection end 48 extending from thecentral section 46 opposite an insert end 50 of the central section 46,with the insert end 50 in turn abutting the injection nozzle 52. Theinsert end 50 of the central section 46 consists of a generally tubularcentral body 51. The central body 51 has a tubular material feed passage54 extending from the external periphery 56 of the insert end 50radially inwardly to injectingly communicate with the annularcircumferential feed port depression or channel 58 in the otherwiseplanar, radially inwardly extending portion 59 of the axially steppedface 61 of the insert end 50. The inwardly extending portion 59 abutsthe planar radially internally extending portion 53 of a matinglystepped face 55 of the injection nozzle 52. The feed port channel 58 andaxially opposed radially internally extending portion 53 of theinjection nozzle 52 cooperatively provide an annular feed port 57disposed transversely laterally, or radially outwardly, from the axis Aof a preferably non-linear injection passage 60 in the injection nozzle52.

The tubular body 51 of the insert, end 50 is secured within and adjacentthe interior periphery 64 of the reactor body 44. The mechanism forsecuring the insert end 50 in this position may consist of anaxially-extending nut-and-bolt arrangement (not shown) penetratingco-linearly mating passages (not shown) in: (i) an upper radiallyextending lip 66 on the reactor body 44; (ii) an abutting, radiallyoutwardly extending thickened neck section 68 on the insert end 50; and(iii) in turn, the abutting injector nozzle 52. Other mechanisms forsecuring the insert end 50 within the reactor body 44 may include apress fit (not shown) or mating threads (not shown) on the outerperiphery 62 of the tubular body 51 and on the inner periphery 64 of thereactor body 44. Seals, e.g., 70, may be mounted as desired between, forexample, the radially extending lip 66 and the abutting the neck section68 and the neck section 68 and the abutting injector nozzle 52.

The non-linear injection passage 60 has, from an axially-extendingcross-sectional perspective, mating, radially inwardly curved opposingside wall sections 72, 74 extending along the axial length of thenon-linear injection passage 60. The entry end 76 of injection passage60 provides a rounded circumferential face abutting an injection feedtube 78, which can be bolted (not shown) to the mating planar, radiallyoutwardly extending distal face 80 on the injection nozzle 52.

In the embodiment of FIG. 2, the injection passage 60 is a DeLaval typeof nozzle and has an axially convergent section 82 abutting anintermediate relatively narrower throat section 84, which in turn abutsan axially divergent section 86. The injection passage 60 also has acircular diametric cross-section (i.e., in cross-sectional viewperpendicular to the axis of the nozzle passage) all along its axiallength. In certain embodiments, the injection passage 60 may alsopresent a somewhat roundly curved thick 82, less curved thicker 84, andrelatively even less curved and more gently sloped relatively thin 86axially extending cross-sectional configuration from the entry end 76 tothe injection end 88 of the injection passage 60 in the injection nozzle52.

The injection passage 60 can thus be configured to present asubstantially isentropic or frictionless configuration for the injectionnozzle 52. This configuration may vary, however, depending on theapplication involved in order to yield a substantially isentropicconfiguration for the application.

The injection passage 60 is formed in a replaceable injection nozzleinsert 90 press-fit or threaded into a mating injection nozzle mountingpassage 92 extending axially through an injection nozzle body 94 of theinjection nozzle 52. The injection nozzle insert 90 is preferably madeof hardened steel alloy, and the balance of the nozzle reactor 100components other than seals, if any, are preferably made of steel orstainless steel.

In the particular embodiment shown in FIG. 2, the diameter D within theinjection passage 60 is 140 mm. The diameter E of the ejection passageopening 96 in the ejection end 48 of the reactor body 44 is 2,2 meters.The axial length of the reactor body 44, from the injection end 88 ofthe injector passage 60 to the ejection passage opening 96, is 10meters.

The interior peripheries 89, 91 of the insert end 50 and the tubularcentral section 46, respectively, cooperatively provide a stepped ortelescoped structure expanding radially outwardly from the injection end88 of the injection passage 60 toward the frustoconical end 48 of thereactor body 44. The particular dimensions of the various components,however, will vary based on the particular application for the nozzlereactor, generally 100. Factors taken into account in determining theparticular dimensions include the physical properties of the crackinggas (density, enthalpy, entropy, heat capacity, etc.) and the pressureratio from the entry end 76 to the injection end 88 of the injectionpassage 60.

The embodiment of FIG. 2 may be used to, for example, crack heavyhydrocarbon material, including bitumen if desired, into lighterhydrocarbons and other components. In order to do so in certainembodiments, superheated steam (not shown) is injected into theinjection passage 60. The pressure differential from the entry end 76,where the pressure is relatively high, to the ejection end 88, where thepressure is relatively lower, aids in accelerating the superheated steamthrough the injection passage 60.

In certain embodiments having one or more non-linear cracking materialinjection passages, e.g., 60, such as the convergent/divergentconfiguration of FIG. 2, the pressure differential can yield a steadyincrease in the kinetic energy of the cracking material as it movesalong the axial length of the cracking material injection passage(s) 60.The cracking material may thereby eject from the ejection end 88 of theinjection passage 60 into the interior of the reactor body 44 atsupersonic speed with a commensurately relatively high level of kineticenergy. In these embodiments, the level of kinetic energy of thesupersonic discharge cracking material is therefore greater than can beachieved by certain prior art straight-through injectors or otherinjectors such as the convergent, divergent, convergent nozzle reactorof the '615 Publication.

Other embodiments of a cracking material injection passage may not be asisentropic but may provide a substantial increase in the speed andkinetic energy of the cracking material as it moves through theinjection passage 60. For example, an injection passage 60 may comprisea series of conical or toroidal sections (not shown) to provide varyingcracking material acceleration through the passage 60 and, in certainembodiments, supersonic discharge of the cracking material from thepassage 60.

In certain methods of use of the nozzle reactor embodiment illustratedin FIG. 2, heavy hydrocarbon feed stock (not shown) is pre-heated, forexample at 2-15 bar, which is generally the same pressure as that in thereactor body 44. In the case of bitumen feed stock, the preheat shouldprovide a feed stock temperature of 300 to 500°, and most advantageously400 to 450° C. Contemporaneously, the preheated feed stock is injectedinto the Material feed passage 54 and then through the mating annularfeed port 57. The feed stock thereby travels radially inwardly to impacta transversely (i.e., axially) traveling high speed cracking materialjet (for example, steam, natural gas, carbon dioxide or other gas notshown) virtually immediately upon its ejection from the ejection end 88of the injection passage 60. The collision of the radially injected feedstock with the axially traveling high speed steam jet delivers kineticenergy to the feed stock. The applicants believe that this process maycontinue, but with diminished intensity and productivity, through thelength of the reactor body 44 as injected feed stock is forced along theaxis of the reactor body 44 and yet constrained from avoiding contactwith the jet stream by the telescoping interior walls, e.g., 89, 91 101,of the reactor body 44. Depending on the nature of the feed stock andits pre-feed treatment, differing results can be procured, such ascracking of heavy hydrocarbons, including bitumen, into lighterhydrocarbons and, if present in the heavy hydrocarbons or injectedmaterial, other materials.

In some embodiments, a catalyst can be introduced into the nozzlereactor to enhance cracking of the material feed stock by the crackinggas ejection stream.

In the applicant's view, the methodology of nozzles of the type shown inthe illustrated embodiments, to inject a cracking gas such as steam, canbe based on the following equation

KE ₁ =H ₁ −H ₀ +KE ₀  (1)

where KE₁ is the kinetic energy of the cracking material (referred to asthe free jet) immediately upon emission from an injection nozzle, H₀ isthe enthalpy of cracking material upon entry into the injection nozzle,H₁ is the enthalpy of cracking material upon emission from the injectionnozzle, and KE₀ is the kinetic energy of the cracking material at theinlet of the nozzle.

This equation derives from the first law of thermodynamics—thatregarding the conservation of energy—in which the types of energy to beconsidered include: potential energy, kinetic energy, chemical energy,thermal energy, and work energy. In the case of the use of the nozzlesof the illustrated embodiments to inject steam, the only significantlypertinent types of energy are kinetic energy and thermal energy. Theothers potential, chemical, and work energy—can be zero or low enough tobe disregarded. Also, the inlet kinetic energy can be low enough to bedisregarded. Thus, the resulting kinetic energy of the cracking materialas set forth in the above equation is simplified to the change inenthalpy ΔH.

The second law of thermodynamics—an expression of the universal law ofincreasing entropy, stating that the entropy of an isolated system thatis not in equilibrium will tend to increase over time, approaching amaximum value at equilibrium means that no real process is perfectlyisentropic. However, a practically isentropic nozzle (i.e., a nozzlecommonly referred to as “isentropic” in the art) is one in which theincrease in entropy through the nozzle results in a relatively completeor very high conversion of thermal energy into kinetic energy. On theother hand, non-isentropic nozzles such as a straight-bore nozzle notonly result in much less efficiency in conversion of thermal energy intokinetic energy but also can impose upper limits on the amount of kineticenergy available from them.

For example, since the velocity of an ideal gas through a nozzle isrepresented by the equation

V=(−2ΔH)^(1/2)  (2)

and the velocity in a straight-bore nozzle is limited to the speed ofsound, the kinetic energy of a gas jet delivered by a straight-borenozzle is limited. However, a practically “isentropic”converging/diverging nozzle, such as shown in, for example, FIGS. 1 and2, can yield, i.e., eject, a gas jet that is supersonic. Consequently,the kinetic energy of the gas jet delivered by such an isentropicconverging/diverging nozzle can be substantially greater than that ofthe straight-bore nozzle, such as that shown in the '181 Publication.

It can thus be seen that certain embodiments disclosed above can providea nozzle reactor providing enhanced transfer of kinetic energy to thematerial feed stock through many aspects such as, for example, byproviding a supersonic cracking gas jet, improved orientation of thedirection of flow of a cracking gas (or cracking gas mixture) withrespect to that of the material feed stock, and/or more completecracking gas stream impact with the material feed stock as a result of,for example, an annular material feed port and the telescoped reactorbody interior. Certain embodiments also can result in reduced retentionof by-products, such as coking, on the side walls of the reactorchamber. Embodiments of the nozzle reactor can also be relatively rapidin operation, efficient, reliable, easy to maintain and repair, andrelatively economical to make and use.

It should be noted that, in certain embodiments including in conjunctionwith the embodiments shown in FIGS. 1 and 2 above, the injectionmaterial may comprise a cracking fluid or other motive material ratherthan, or in addition to, a cracking gas. Accordingly, it is to beunderstood that certain embodiments may utilize components that comprisemotive material compatible components rather than, as described inparticular embodiments above, cracking material compatible componentssuch as, for example, the injection passage, e.g., 60, referenced above.When utilized in conjunction with an inwardly narrowed motive materialinjection passage, however, the motive material preferably iscompressible.

The applicants believe that a non-linear injector passage nozzle reactorembodiment (as generally shown in FIG. 1) and a linear injector passagenozzle reactor one inch in axial length provide the followingtheoretical results for 30 bar steam cracking material supplied at 660°C. with interior reactor chamber pressures of 10 bar and 3 bar as shown.For both of these types of nozzle reactors, however, the injectorpassage configurations must be changed (by varying the position of thethroat 84 and the diameter of the discharge or injection end 88) inorder to deliver 2 barrels per day (water volume) of steam at 10 barsand 3 bars. The results listed in Table 2 are based on the assumption ofperfect gas behavior and the use of k (C_(p)/C_(v), ratio of specificheats).

TABLE 2 Straight-Through Convergent/Divergent Injector Nozzle reactorInjection 10 bar 3 bar 10 bar 3 bar Throat Diameter, mm 1.60 2.80 1.201.20 Steam Temp., ° C. 560.0 544.3 464.4 296.7 Steam Velocity, m/s 647.1690.0 914.1 1244.1 Mach Number 0.93 1.00 1.39 2.12 Kinetic energy, kW0.72 1.12 1.43 2.64

As can be seen from the results of applicants' calculations above, thetheoretically tested straight-through injection passage nozzle reactorsof the prior art theoretically provide steam jet velocity at, or lessthan, the speed of sound. In contrast, the theoretically testedconvergent/divergent injection passage nozzle reactors of the presentapplication theoretically can provide a steam jet velocity in theinterior reactor chamber well in excess of the speed of sound and, at 3bar interior reactor chamber pressure, in excess of twice the speed ofsound. Similarly and as a result, the associated kinetic energies ofsteam jets of the convergent/divergent injection passage nozzle reactorsare theoretically significantly greater than the associated kineticenergies of the steam jets of the linear injection passage nozzlereactors.

The applicants therefore believe that the theoretically testedconvergent/divergent injection passage nozzle reactors of the presentapplication are significantly closer to isentropic than thetheoretically tested straight-through injection passage nozzle reactor.As shown by the theoretical kinetic energy data above, the applicantsalso believe that the theoretically tested convergent/divergentinjection passage nozzle reactors can be 2 to 2.5 times more efficientthan the theoretically tested straight-through injection passage nozzlereactors identified above. The above theoretical results were obtainedusing steam as the cracking material and therefore, are based onthermodynamic properties of steam. However, similar theoretical resultscan be obtained using other gaseous motive fluids as the cracking gas.

Similarly, the kinetic energies of cracking gas jet of theconvergent/divergent injection passage nozzle reactors can also besignificantly greater than the associated kinetic energies of the mediumof the convergent/divergent/convergent injection passage of the typedisclosed in the '615 Publication.

In the convergent/divergent/convergent injection passage of the '615Publication, however, the velocity and kinetic energy of thebitumen/steam medium is designed to substantially decrease at least viathe second convergent section, thus diminishing the ultimate velocityand kinetic energy of the medium when ejected from the '615Publication's nozzle reactor. In addition, the '615 Publication's use ofa mixed bitumen/steam medium itself reduces the velocity of the mediumas compared to the velocities, and resulting shear, attainable byinjection of separate steam and pre-heated bitumen feeds, for example.

Certain embodiments of the present reactor nozzle and method of use cantherefore accomplish cracking of bitumen and other feed stocksprimarily, or at least more substantially, by mechanical shear at amolecular level rather than by temperature, retention time, orinvolvement of catalysts. Although such cracking of the hydrocarbonmolecules yields smaller, charge imbalanced hydrocarbon chains whichsubsequently satisfy their charge imbalance by chemical interaction withother materials in the mixed jet stream or otherwise, the driving forceof the hydrocarbon cracking process can be mechanical rather thanchemical. In addition, certain embodiments can utilize the greatersusceptibility of at least certain heavy hydrocarbons to mechanicalcracking in order to selectively crack particular hydrocarbons (such asrelatively heavy bitumen for example) as opposed to other lighterhydrocarbons or other materials that may be in the material feed stockas it passes through the nozzle reactor.

Also, in certain embodiments, the configuration of the nozzle reactorcan reduce and even virtually eliminate back mixing while enhancing, forexample, plug flow of the cracking material and material feed mixturethrough the reactor body and cooling of the mixture through the reactorbody. This can aid in not only enhancing mechanical cracking of thematerial feed but also in reducing coke formation and wall seatingwithin the reactor body. In combination with injection of a highvelocity cracking material or other motive material from the injectionnozzle into the reactor body, coke formation and wall scaling can beeven more significantly reduced if not virtually or practicallyeliminated. In these embodiments, the nozzle reactor can thus providemore efficient and complete cracking, and if desired selective cracking,of heavy hydrocarbons, while reducing and in certain embodimentsvirtually eliminating wail scaling within the reactor body.

Another embodiment of a nozzle reactor suitable for use in the methodsand systems described herein is illustrated in FIGS. 3 to 8. FIGS. 3 and4 show cross-sectional views of one embodiment of a nozzle reactor 1000suitable for use in the methods described herein. The nozzle reactor1000 includes a head portion 1002 coupled to a body portion 1004. A mainpassage 1006 extends through both the head portion 1002 and the bodyportion 1004. The head and body portions 1002, 1004 are coupled togetherso that the central axes of the main passage 1006 in each portion 1002,1004 are coaxial so that the main passage 1006 extends straight throughthe nozzle reactor 1000.

It should be noted that for purposes of this disclosure, the term“coupled” means the joining of two members directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two members or the two members andany additional intermediate members being integrally formed as a singleunitary body with one another or with the two members or the two membersand any additional intermediate member being attached to one another.Such joining may be permanent in nature or alternatively may beremovable or releasable in nature.

The nozzle reactor 1000 includes a feed passage 1008 that is in fluidcommunication with the main passage 1006. The feed passage 1008intersects the main passage 1006 at a location between the portions1002, 1004. The main passage 1006 includes an entry opening 1010 at thetop of the head portion 1002 and an exit opening 1012 at the bottom ofthe body portion 1004. The feed passage 1008 also includes an entryopening 1014 on the side of the body portion 1004 and an exit opening1016 that is located where the feed passage 1008 meets the main passage1006.

During operation, the nozzle reactor 1000 includes a reacting fluid thatflows through the main passage 1006. The reacting fluid enters throughthe entry opening 1010, travels the length of the main passage 1006, andexits the nozzle reactor 1000 out of the exit opening 1012. A feedmaterial flows through the feed passage 1008. The feed material entersthrough the entry opening 1014, travels through the feed passage 1006,and exits into the main passage 1008 at exit opening 1016.

The main passage 1006 is shaped to accelerate the reacting fluid. Themain passage 1006 may have any suitable geometry that is capable ofdoing this. As shown in FIGS. 3 and 4, the main passage 1006 includes afirst region having a convergent section 1020 (also referred to hereinas a contraction section), a throat 1022, and a divergent section 1024(also referred to herein as an expansion section). The first region isin the head portion 1002 of the nozzle reactor 1000.

The convergent section 1020 is where the main passage 1006 narrows froma wide diameter to a smaller diameter, and the divergent section 1024 iswhere the main passage 1006 expands from a smaller diameter to a largerdiameter. The throat 1022 is the narrowest point of the main passage1006 between the convergent section 1020 and the divergent section 1024.When viewed from the side, the main passage 1006 appears to be pinchedin the middle, making a carefully balanced, asymmetric hourglass-likeshape. This configuration is commonly referred to as aconvergent-divergent nozzle or “con-di nozzle”.

The convergent section of the main passage 1006 accelerates subsonicfluids since the mass flow rate is constant and the material mustaccelerate to pass through the smaller opening. The flow will reachsonic velocity or Mach 1 at the throat 1022 provided that the pressureratio is high enough. In this situation, the main passage 1006 is saidto be in a choked flow condition.

Increasing the pressure ratio further does not increase the Mach numberat the throat 1022 beyond unity. However, the flow downstream from thethroat 1022 is free to expand and can reach supersonic velocities. Itshould be noted that Mach 1 can be a very high speed for a hot fluidsince the speed of sound varies as the square root of absolutetemperature. Thus the speed reached at the throat 1022 can be far higherthan the speed of sound at sea level.

The divergent section 1024 of the main passage 1006 slows subsonicfluids, but accelerates sonic or supersonic fluids. Aconvergent-divergent geometry can therefore accelerate fluids in achoked flow condition to supersonic speeds. The convergent-divergentgeometry can be used to accelerate the hot, pressurized reacting fluidto supersonic speeds, and upon expansion, to shape the exhaust flow sothat the heat energy propelling the flow is maximally converted intokinetic energy.

The flow rate of the reacting fluid through the convergent-divergentnozzle is isentropic (fluid entropy is nearly constant). At subsonicflow the fluid is compressible so that sound, a small pressure wave, canpropagate through it. At the throat 1022, where the cross sectional areais a minimum, the fluid velocity locally becomes sonic (Machnumber=1.0). As the cross sectional area increases the gas begins toexpand and the gas flow increases to supersonic velocities where a soundwave cannot propagate backwards through the fluid as viewed in the frameof reference of the nozzle (Mach number >1.0).

The main passage 1006 only reaches a choked flow condition at the throat1022 if the pressure and mass flow rate is sufficient to reach sonicspeeds, otherwise supersonic flow is not achieved and the main passagewill act as a venturi tube. In order to achieve supersonic flow, theentry pressure to the nozzle reactor 1000 should be significantly aboveambient pressure.

The pressure of the fluid at the exit of the divergent section 1024 ofthe main passage 1006 can be low, but should not be too low. The exitpressure can be significantly below ambient pressure since pressurecannot travel upstream through the supersonic flow. However, if thepressure is too far below ambient, then the flow will cease to besupersonic or the flow will separate within the divergent section 1024of the main passage 1006 forming an unstable jet that “flops” around anddamages the main passage 1006. In one embodiment, the ambient pressureis no higher than approximately 2-3 times the pressure in the supersonicgas at the exit.

The supersonic reacting fluid collides and mixes with the feed materialin the nozzle reactor 1000 to produce the desired reaction. The highspeeds involved and the resulting collision produces a significantamount of kinetic energy that helps facilitate the desired reaction. Thereacting fluid and/or the feed material may also be pre-heated toprovide additional thermal energy to react the materials.

The nozzle reactor 1000 may be configured to accelerate the reactingfluid to at least approximately Mach 1, at least approximately Mach 1.5,or, desirably, at least approximately Mach 2. The nozzle reactor mayalso be configured to accelerate the reacting fluid to approximatelyMach 1 to approximately Mach 7, approximately Mach 1.5 to approximatelyMach 6, or, desirably, approximately Mach 2 to approximately Mach 5.

As shown in FIG. 4, the main passage 1006 has a circular cross-sectionand opposing converging side walls 1026, 1028. The side walls 1026, 1028curve inwardly toward the central axis of the main passage 1006. Theside walls 1026, 1028 form the convergent section 1020 of the mainpassage 1006 and accelerate the reacting fluid as described above.

The main passage 1006 also includes opposing diverging side walls 1030,1032. The side walls 1030, 1032 curve outwardly (when viewed in thedirection of flow) away from the central axis of the main passage 106.The side walls 1030, 1032 form the divergent section 1024 of the mainpassage 106 that allows the sonic fluid to expand and reach supersonicvelocities.

The side walls 1026, 1028, 1030, 1032 of the main passage 1006 provideuniform axial acceleration of the reacting fluid with minimal radialacceleration. The side walls 1026, 1028, 1030, 1032 may also have asmooth surface or finish with an absence of sharp edges that may disruptthe flow. The configuration of the side walls 1026, 1028, 1030, 1032renders the main passage 1006 substantially isentropic.

The feed passage 1008 extends from the exterior of the body portion 1004to an annular chamber 1034 formed by head and body portions 1002, 1004.The portions 1002, 1004 each have an opposing cavity so that when theyare coupled together the cavities combine to form the annular chamber1034. A seal 1036 is positioned along the outer circumference of theannular chamber 1034 to prevent the feed material from leaking throughthe space between the head and body portions 1002, 1004.

It should be appreciated that the head and body portions 1002, 1004 maybe coupled together in any suitable manner. Regardless of the method ordevices used, the head and body portions 1002, 1004 should be coupledtogether in a way that prevents the feed material from leaking andwithstands the forces generated in the interior. In one embodiment, theportions 1002, 1004 are coupled together using bolts that extend throughholes in the outer flanges of the portions 1002, 1004.

The nozzle reactor 1000 includes a distributor 1040 positioned betweenthe head and body portions 1002, 1004. The distributor 1040 prevents thefeed material from flowing directly from the opening 1041 of the feedpassage 1008 to the main passage 1006. Instead, the distributor 1040annularly and uniformly distributes the feed material into contact withthe reacting fluid flowing in the main passage 1006.

As shown in FIG. 6, the distributor 1040 includes an outer circular wall1048 that extends between the head and body portions 1002, 1004 andforms the inner boundary of the annular chamber 1034. A seal or gasketmay be provided at the interface between the distributor 140 and thehead and body portions 1002, 1004 to prevent feed material from leakingaround the edges.

The distributor 1040 includes a plurality of holes 1044 that extendthrough the outer wall 1048 and into an interior chamber 1046. The holes1044 are evenly spaced around the outside of the distributor 1040 toprovide even flow into the interior chamber 1046. The interior chamber1046 is where the main passage 1006 and the feed passage 1008 meet andthe feed material conies into contact with the supersonic reactingfluid.

The distributor 1040 is thus configured to inject the feed material atabout a 90° angle to the axis of travel of the reacting fluid in themain passage 1006 around the entire circumference of the reacting fluid.The feed material thus forms an annulus of flow that extends toward themain passage 1006. The number and size of the holes 1044 are selected toprovide a pressure drop across the distributor 1040 that ensures thatthe flow through each hole 1044 is approximately the same. In oneembodiment, the pressure drop across the distributor is at leastapproximately 2000 pascals, at least approximately 3000 pascals, or atleast approximately 5000 pascals.

The distributor 1040 includes a wear ring 1050 positioned immediatelyadjacent to and downstream of the location where the feed passage 108meets the main passage 1006. The collision of the reacting fluid and thefeed material causes a lot of wear in this area. The wear ring is aphysically separate component that is capable of being periodicallyremoved and replaced.

As shown in FIG. 6, the distributor 1040 includes an annular recess 1052that is sized to receive and support the wear ring 1050. The wear ring1050 is coupled to the distributor 1040 to prevent it from moving duringoperation. The wear ring 1050 may be coupled to the distributor in anysuitable manner. For example, the wear ring 1050 may be welded or boltedto the distributor 1040. If the wear ring 1050 is welded to thedistributor 1040, as shown in FIG. 5, the wear ring 1050 can be removedby grinding the weld off. In some embodiments, the weld or bolt need notprotrude upward into the interior chamber 1046 to a significant degree.

The wear ring 1050 can be removed by separating the head portion 1002from the body portion 1004. With the head portion 1002 removed, thedistributor 1040 and/or the wear ring 1050 are readily accessible. Theuser can remove and/or replace the wear ring 1050 or the entiredistributor 1040, if necessary.

As shown in FIGS. 3 and 4, the main passage 1006 expands after passingthrough the wear ring 1050. This can be referred to as expansion area1060 (also referred to herein as an expansion chamber). The expansionarea 1060 is formed largely by the distributor 1040, but can also beformed by the body portion 1004.

Following the expansion area 1060, the main passage 1006 includes asecond region having a converging-diverging shape. The second region isin the body portion 1004 of the nozzle reactor 1000. In this region, themain passage includes a convergent section 1070 (also referred to hereinas a contraction section), a throat 1072, and a divergent section 1074(also referred to herein as an expansion section). Theconverging-diverging shape of the second region differs from that of thefirst region in that it is much larger. In one embodiment, the throat1072 is at least 2-5 times as large as the throat 1022.

The second region provides additional mixing and residence time to reactthe reacting fluid and the feed material. The main passage 1006 isconfigured to allow a portion of the reaction mixture to flow backwardfrom the exit opening 1012 along the outer wall 1076 to the expansionarea 1060. The backflow then mixes with the stream of material exitingthe distributor 1040. This mixing action also helps drive the reactionto completion.

The dimensions of the nozzle reactor 1000 can vary based on the amountof material that is fed through it. For example, at a flow rate ofapproximately 590 kg/hr, the distributor 140 can include sixteen holes144 that are 3 mm in diameter. The dimensions of the various componentsof the nozzle reactor shown in FIGS. 3 and 4 are not limited, and maygenerally be adjusted based on the amount of feed flow rate if desired.Table 3 provides exemplary dimensions for the various components of thenozzle reactor 1000 based on a hydrocarbon feed input measured inbarrels per day (BPD).

TABLE 3 Exemplary nozzle reactor specifications Feed Input (BPD) NozzleReactor Component (mm) 5,000 10,000 20,000 Main passage, first region,entry opening 254 359 508 diameter Main passage, first region, throatdiameter 75 106 150 Main passage, first region, exit opening 101 143 202diameter Main passage, first region, length 1129 1290 1612 Wear ringinternal diameter 414 585 828 Main passage, second region, entry opening308 436 616 diameter Main passage, second region, throat diameter 475672 950 Main passage, second region, exit opening 949 1336 1898 diameterNozzle reactor, body portion, outside diameter 1300 1830 2600 Nozzlereactor, overall length 7000 8000 10000

It should be appreciated that the nozzle reactor 1000 can be configuredin a variety of ways that are different than the specific design shownin the Figures. For example, the location of the openings 1010, 1012,1014, 1016 may be placed in any of a number of different locations.Also, the nozzle reactor 1000 may be made as an integral unit instead ofcomprising two or more portions 1002, 1004. Numerous other changes maybe made to the nozzle reactor 1000.

Turning to FIGS. 7 and 8, another embodiment of a nozzle reactor 2000 isshown. This embodiment is similar in many ways to the nozzle reactor1000. Similar components are designated using the same reference numberused to illustrate the nozzle reactor 1000. The previous discussion ofthese components applies equally to the similar or same componentsincludes as part of the nozzle reactor 2000.

The nozzle reactor 2000 differs a few ways from the nozzle reactor 1000.The nozzle reactor 2000 includes a distributor 2040 that is formed as anintegral part of the body portion 2004. However, the wear ring 1050 isstill a physically separate component that can be removed and replaced.Also, the wear ring 1050 depicted in FIG. 18 is coupled to thedistributor 2040 using bolts instead of by welding. It should be notedthat the bolts are recessed in the top surface of the wear ring 1050 toprevent them from interfering with the flow of the feed material.

In FIGS. 7 and 8, the head portion 1002 and the body portion 1004 arecoupled together with a clamp 2080. The seal, which can be metal orplastic, resembles a “T” shaped cross-section. The leg 2082 of the “T”forms a rib that is held by the opposing faces of the head and bodyportions 1002, 1004. The two arms or lips 2084 form seals that create anarea of sealing surface with the inner surfaces 2076 of the portions1002, 1004. Internal pressure works to reinforce the seal.

The clamp 2080 fits over outer flanges 2086 of the head and bodyportions 1002, 1004. As the portions 1002, 1004 are drawn together bythe clamp, the seal lips deflect against the inner surfaces 2076 of theportions 1002, 1004. This deflection elastically loads the lips 2084against the inner surfaces 2076 forming a self-energized seal. In oneembodiment, the clamp is made by Grayloc Products, located in Houston,Tex.

In some embodiments, a nozzle reactor system may be used to increase theoverall conversion of material feed into lighter components viacracking. The nozzle reactor system described herein may achieve thisincrease in overall conversion by utilizing a first nozzle reactor toconduct a first cracking step, and then passing any material not crackedor not sufficiently cracked by the first nozzle reactor into a secondnozzle reactor that operates under conditions selected for cracking theuncracked or not sufficiently cracked material.

As shown in FIG. 9, the nozzle reactor system 300 may generally includea first nozzle reactor 310 and a second nozzle reactor 320. Nozzlereactor system 300 may also include a first separation unit 330. Firstseparation unit 330 may generally separate the material leaving firstnozzle reactor 310 into a light stream and a heavy stream. Accordingly,first separation unit 330 may include a light stream outlet 332 and aheavy stream outlet 334. Heavy stream outlet 334 may be in fluidcommunication with the material feed passage of second nozzle reactor320 so that the heavy components of heavy stream outlet 334 may betransported to second nozzle reactor 320 for cracking.

First and second nozzle reactors 310, 320 may generally include a nozzlereactor according to any embodiment or aspect described herein. In oneaspect, first and second nozzle reactors 310, 320 may each have areactor body, an injection passage, and a material feed passage. Thereactor body may include an interior reactor chamber with an injectionend and an ejection end. The injection passage may be mounted in thenozzle reactor in material injecting communication with the injectionend of the interior reactor chamber. Furthermore, the injection passagemay have an enlarged volume injection section, an enlarged volumeelection section, and a reduced volume mid-section intermediate theenlarged volume injection section and enlarged volume ejection section.The injection passage may also have a material injection end and amaterial ejection end in injecting communication with the interiorreactor chamber. The material feed passage may penetrate the reactorbody. The location of the material feed passage may be adjacent to thematerial ejection end of the injection passage and transverse to aninjection passage axis extending from the material injection end to thematerial ejection end in the injection passage.

First and second nozzle reactors 310, 320 may be identical or first andsecond nozzle reactors 310, 320 may be different. In one aspect of theembodiment, second nozzle reactor 320 has a smaller interior bodychamber volume than the interior reactor chamber volume of first nozzlereactor 310. For example, the interior reactor chamber volume of secondnozzle reactor 320 may be ⅓ or less the interior reactor chamber volumeof first nozzle reactor 310. Additionally, nozzle reactor system 300 mayinclude more than two nozzle reactors. Other features of the nozzlereactor are described in greater detail above.

First separation unit 330 may generally include any type of separationunit capable of separating the lighter material that is the product ofcracking the material feed fed into first nozzle reactor 310 from theheavy material that may generally be made up of material feed that wasnot cracked or not sufficiently cracked in first nozzle reactor 310.Examples of suitable separation units include, but are not limited to,distillation units, gravity separation units, filtration units, andcyclonic separation units.

First separation unit 330 may be in fluid communication with theejection end of first nozzle reactor 310 such that the material leavingfirst nozzle reactor 310 is fed into first separation unit 330. Anymanner of fluid communication may be used between first nozzle reactor310 and first separation unit 330. In one example, the fluidcommunication may be piping extending between the ejection end of firstnozzle reactor 310 and first separation unit 330.

As noted above, first separation unit 330 may generally include lightstream outlet 332 and heavy stream outlet 334. Light stream outlet 332may generally include any materials having a predetermined property orproperties, such as a molecular weight, boiling point, API gravity, orviscosity. As such, light stream outlet 332 may include, for example, a)material feed that is not cracked inside first nozzle reactor 310 butthat possessed a predetermined property prior to being introduced intofirst nozzle reactor 310, and b) material feed that has been crackedinside first nozzle reactor 310 such that the cracked material obtainsthe predetermined property. Thus, where the material feed injected intofirst nozzle reactor 310 via the material feed passage is bitumen, lightstream outlet 332 may comprise uncracked hydrocarbons that had thepredetermined property when injected into first nozzle reactor 310 andcracked hydrocarbon molecules that obtained the predetermined propertyupon being cracked inside of first nozzle reactor 310. Correspondingly,heavy stream outlet 334 may generally include any materials not havingthe predetermined property or properties. As such, heavy stream outlet334 may include, for example, a) material feed that is not crackedinside first nozzle reactor 310 and that did not possess thepredetermined property upon being introduced into first nozzle reactor310, and b) material feed that has been cracked inside first nozzlereactor 310 but that did not result in the cracked material possessingthe predetermined property. Thus, where the material feed is bitumen,heavy stream outlet 334 may include uncracked hydrocarbon molecules thatdid not have the predetermined property when injected into first nozzlereactor 310 and cracked hydrocarbon molecules that did not obtain thepredetermined property upon being cracked inside of first nozzle reactor310.

Any property, property value Or property range may be selected todetermine whether a material is part of light stream outlet 332 or heavystream outlet 334. Examples of properties and property values that maybe used to classify the material leaving first nozzle reactor 310 mayinclude a molecular weight above a selected value, a molecular weightbelow a selected value, a molecular weight within a selected range, aboiling point above a selected value, a boiling point below a selectedvalue, a boiling point within a selected range, an API gravity above aselected value, an API gravity below a selected value, an API within aselected range, a viscosity above a selected value, a viscosity below aselected value, or a viscosity within a selected range. Furthermore,multiple properties may be used to determine whether a material leavingfirst nozzle reactor 310 is part of light stream outlet 332 or heavystream outlet 334. For example, the material may have to have both amolecular weight below a selected value and a boiling point below aselected value to be part of light stream outlet 332. The value or rangeselected for the property is also not limited. The value or range ofvalues selected may be based on known property values for usefulfractions of a material feed.

In order to transport the components of heavy stream outlet 334 tosecond nozzle reactor 320, a fluid communication may be establishedbetween heavy stream outlet 334 and second nozzle reactor 320. Morespecifically, a fluid communication may be established between heavystream outlet 334 and the material feed passage of second nozzle reactor320. However, fluid communication may also be established between heavystream outlet 334 and any portion of second nozzle reactor 320. Anymanner of fluid communication may be used between second nozzle reactor320 and heavy stream outlet 334. In one example, the fluid communicationmay be piping extending between the heavy stream outlet 334 and secondnozzle reactor 320. A pump may also be used in connection with the fluidcommunication to assist the flow of material through the fluidcommunication.

Second nozzle reactor 320 may be operated at different operatingconditions than first nozzle reactor 310 so as to increase thelikelihood of cracking the components of heavy stream outlet 334. It isgenerally theorized that nozzle reactors as described herein crack themolecules having the largest molecular mass first. In first nozzlereactor 310, a relatively high operating temperature may be selectedsuch that only a high boiling point fraction of the feed material ispresent in the reaction chamber as a liquid (or possibly a solid), whilethe remaining fractions are present in the reaction chamber as a gas. Assuch, the fraction that is present in the reaction chamber as a liquidor solid has the largest molecular mass and will be the first materialcracked by the shock waves produced inside the nozzle reactor. Gaseousfractions may pass through the reaction chamber without being cracked.These gaseous fractions may then become part of the heavy stream fed tosecond nozzle reactor 320. If second nozzle reactor 320 is operated atthe same operating conditions as first nozzle reactor 310, the heavystream will remain in the gas phase and likely pass through secondnozzle reactor 320 with no further cracking being accomplished.Accordingly, the operating conditions that may be altered between thefirst and second nozzle reactors 310, 320 are those which will increasethe mass of the components of heavy stream outlet 334 as they entersecond nozzle reactor 320. In other words, operating second nozzlereactor 320 under conditions that will transform the gaseous heavystream into a liquid or solid may increase the rate at which secondnozzle reactor 320 cracks the components of heavy stream outlet 334.Exemplary operating conditions that may be altered between first nozzlereactor 310 and second nozzle reactor 320 and that will increase themass of the components of heavy stream outlet 334 include decreasing thetemperature of the components of heavy stream outlet 334. Reduction intemperature may be achieved by reducing the ratio of cracking materialmass to material feed mass or by reducing the superheat in the crackingmaterial while maintaining the ratio of cracking material mass tomaterial feed mass.

In another aspect of this embodiment, nozzle reactor system 300 mayfurther include a second separation unit 340. Second separation unit 340may be in fluid communication with the ejection end of second nozzlereactor 320 such that material leaving second nozzle reactor 320 is fedinto second separation unit 340. Second separation unit 340 maygenerally include a light stream outlet 342 and a heavy stream outlet344.

Like first separation unit 330, second separation unit 340 may generallyinclude any type of separation unit capable of separating lightermaterial that possesses a predetermined property when leaving secondnozzle reactor 320 from the heavy material that does not possesses thepredetermined property when leaving second nozzle reactor 320. Examplesof suitable separation units include, but are not limited to,distillation units, gravity separation units, filtration units, andcyclonic separation units.

Second separation unit 340 may be in fluid communication with theejection end of second nozzle reactor 320 such that the material leavingsecond nozzle reactor 320 is fed into second separation unit 340. Anymanner of fluid communication may be used between second nozzle reactor320 and second separation unit 340. In one example, the fluidcommunication may be piping extending between the ejection end of secondnozzle reactor 320 and second separation unit 340.

As noted above, second separation unit 340 may generally include lightstream outlet 342 and heavy stream outlet 344. Light stream outlet 342may generally include material that has a predetermined property orproperties when leaving second nozzle reactor 320. Correspondingly,heavy stream outlet 344 may generally be comprised of material that doesnot have the predetermined property or properties when leaving secondnozzle reactor 320. The predetermined property or properties used toseparate streams in second separation unit 340 need not be the samepredetermined property or properties used to separate streams in firstseparation unit 330. Alternatively, the same predetermined properly orproperties may be used in both first separation unit 330 and secondseparation unit 340. As with first separation unit 330, any property,property value or property value ranged may be selected as the parameterfor separating light and heavy streams.

In one aspect of the embodiment, light stream outlet 342 may be in fluidcommunication with first nozzle reactor 310 or second nozzle reactor 320via a recycle stream. Despite possessing a predetermined property orproperties, the material that makes up light stream outlet 342 may stillbe too large and heavy to be used as useful product, and thus requiresfurther cracking. Such cracking may take place in either first nozzlereactor 310 or second nozzle reactor 320 or both depending on thecharacteristics (such as molecular weight or boiling point) of thematerial that makes up light stream outlet 342. Accordingly, providing afluid communication between light stream outlet 342 and first nozzlereactor 310 and/or second nozzle reactor 320 allows for this secondattempt at cracking the material, although this time in an improvedcondition for cracking. Any manner of fluid communication may be usedbetween light stream output 342 and first nozzle reactor 310 and/orsecond nozzle reactor 320. In one example, the fluid communication maybe piping extending between the light stream output 342 and the materialfeed passage of first nozzle reactor 310 and/or second nozzle reactor320.

A similar recycle stream may be used to divert the material of heavystream outlet 344 back to either first nozzle reactor 310 or secondnozzle reactor 320. The manner of providing such a recycle stream may besimilar to the recycle stream as described above, such as by providingpiping between heavy stream outlet 344 and either first nozzle reactor310 or second nozzle reactor 320.

Similar recycle streams may also be provided between light stream outlet332 and first nozzle reactor 310. Additionally, a portion of heavystream outlet 334 may be recycled back to first nozzle reactor, whilethe remainder of heavy stream outlet 334 is injected into second nozzlereactor 320 as described in greater detail above. Furthermore, a portionof light stream 332 may be recycled back to first nozzle reactor 310.

In the above description, two nozzle reactors are discussed. However,the nozzle reactor system is not limited to two nozzle reactors. Anynumber of nozzle reactors arranged in series may be used. Each nozzlereactor may operate at different conditions, with each nozzle reactoroperating under conditions specifically selected to increase thelikelihood of cracking a material that has passed through a previousnozzle reactor uncracked or not sufficiently cracked. Furthermore, thenozzle reactors may be arranged in parallel in addition to a seriesarrangement. For example, a first nozzle reactor may produce a heavystream and a light stream, with the heavy stream being transported to asecond nozzle reactor and a light stream being transported to a thirdnozzle reactor.

In another embodiment, a material feed cracking method is disclosed. Thematerial feed cracking method may generally allow for an increase inconversion of material feed into lighter components by utilizing two ormore reactor nozzles. The first reactor nozzle is utilized in a similarfashion to the detailed discussion above regarding the nozzle reactor.However, an additional nozzle reactor is used to deal with the materialthat passes through the first nozzle reactor but that is not cracked ornot sufficiently cracked. More specifically, the operating conditions ofthe second nozzle reactor may be selected so that the second nozzlereactor is more likely to break down material that passes through thefirst nozzle reactor uncracked or not sufficiently cracked.

The material feed cracking method may generally include a first step ofinjecting a first stream of cracking material through an injectionpassage of a first nozzle reactor into an interior reactor chamber of afirst nozzle reactor. Material feed may then be injected into theinterior reactor chamber of the first nozzle reactor adjacent to theinjection passage of the first nozzle reactor and transverse to thefirst stream of cracking material entering the interior reaction chamberof the first nozzle reactor from the injection passage of the firstnozzle reactor. In this manner, a first light material and a first heavymaterial may be produced. The method may then include a step ofinjecting a second stream of cracking material through an injectionpassage of a second nozzle reactor into an interior reactor chamber of asecond nozzle reactor. Additionally, the first heavy material may beinjected into the interior reactor chamber of the second nozzle reactoradjacent to the injection passage of the second nozzle reactor andtransverse to the second stream of cracking material entering theinterior reactor chamber of the second nozzle reactor from the injectionpassage of the second nozzle reactor. In this manner, a second lightmaterial and a second heavy material may be produced.

The first and second nozzle reactors referred to above may generallyinclude a nozzle reactor according to any embodiment or aspect describedherein. In one aspect, each nozzle reactor may comprise a reactor body,an injection passage, and a material feed passage. The reactor body mayhave an interior reactor chamber with an injection end and an ejectionend, The injection passage may be mounted in the nozzle reactor inmaterial injecting communication with the injection end of the interiorreactor chamber. Furthermore, the injection passage may have an enlargedvolume injection section, an enlarged volume ejection section, and areduced volume mid-section intermediate the enlarged volume injectionsection and enlarged volume ejection section. The injection passage mayalso have a material injection end and a material ejection end ininjecting communication with the interior reactor chamber. The materialfeed passage may penetrate the reactor body. The location of thematerial feed passage may be adjacent to the material ejection end ofthe injection passage and transverse to an injection passage axisextending from the material injection end to the material ejection endin the injection passage.

The first and second streams of cracking material may be any suitablecracking material for cracking the material feed. In one aspect thecracking material is a cracking gas, such as steam. The first and secondstreams of cracking material may be introduced into the injectionpassages at any suitable temperature and pressure. In one embodiment,the first and second streams of cracking material are injected into theinjection passage at a temperature of from about 600° C. to about 850°C. and at a pressure of from about 15 bar to about 200 bar.

The material feed may be any type of material that may be broken downinto smaller and lighter components. In one aspect of this method, thematerial feed is a hydrocarbon source, such as heavy oil, bitumen, crudeoil, or any residue with a high asphaltene content. The residue may beany residual portion of a separated hydrocarbon stream, such as thebottoms fraction from a distillation unit. The high asphaltene contentmay be an asphaltene content greater than 4 wt % of the residue.Hydrocarbon sources such as these require cracking to break down theheavy and large molecules of the hydrocarbon into light components thatmay be beneficially used.

The material feed and first heavy stream may be introduced into thematerial feed passages at any suitable temperature and pressure. In oneembodiment, the material feed and first heavy stream are injected intothe material feed passages at a temperature of from about 300° C. to500° C. and at a pressure of from about 2 about to about 15 bar.

The pressure inside the interior reactor chamber of the first and secondnozzle reactor may range from about 0.5 bar to about 15 bar. The ratioof cracking material to material feed may range from about 0.5:1.0 toabout 4:1. The ratio of cracking material to first heavy material mayrange from about 0.1:1.0 to about 3:1.0.

As noted above, the injection of the material feed and the first streamof cracking material may result in the production of first lightmaterial and first heavy material. This is because the nozzle reactordoes not achieve total cracking of all material feed injected into thefirst nozzle reactor. The short retention time of the material feed inthe interior reactor chamber combined with the preference of the nozzlereactor to crack the largest molecules first does not allow forshockwaves generated by the injection passage to crack all of thematerial feed, and some material feed will therefore pass all the waythrough the first nozzle reactor without being cracked. Specifically,fractions of the material feed in a gaseous phase when passing throughthe interior reactor chamber may pass through the nozzle reactor withoutbeing cracked. These gaseous fractions may be considerednon-participating in that they will not be cracked by the shock waves.Where such material feed passing through the nozzle uncracked compriseslarge molecules, further work may need to be done to accomplish crackingof the material into useful material.

In one aspect of this embodiment, the operating conditions of the firstnozzle reactor may be selected such that only a fraction of the materialfeed in the nozzle reactor is in a liquid or solid phase, while theremaining fractions of the material feed are in a gaseous phase. Thismay be achieved by, for example, pre-heating the material feed prior toinjection into the nozzle reactor. In an example where the material feedcomprises bitumen, the bitumen may comprise a fraction having a boilingpoint higher than 200 deg C. The pre-heating temperature may be selectedsuch that only this fraction of the bitumen is in liquid or solid form,and therefore is the fraction most likely to be cracked by the firstnozzle reactor. The remaining fractions of the bitumen in the gaseousphase may pass through the first nozzle reactor uncracked, at whichpoint they may be fed to a second nozzle reactor. The temperature of thegaseous material leaving the first nozzle reactor may be altered suchthat the gas transforms into liquid or solid and thereby increases thechances of the material being cracked in the second nozzle reactor.

Accordingly, the first heavy material may be injected into the secondnozzle reactor to undergo another attempt at cracking the material inthe nozzle reactor. The second nozzle reactor may be identical in sizeand dimension to the first nozzle reactor, or may be different than thefirst nozzle reactor. In one aspect of the embodiment, the operatingconditions of the second nozzle reactor are different from the operatingconditions of the first nozzle reactor as described in greater detailabove. For example, the temperature of the material injected into thesecond nozzle reactor may be reduced to add mass to the gaseouscomponents being fed into the second nozzle reactor to better accomplishthe cracking of the hydrocarbons that make up the first heavy materialinjected into the second nozzle reactor.

In another aspect of this embodiment, the first light material and thefirst heavy material leaving the first nozzle reactor may be separatedprior to the introduction of the first heavy material into the secondnozzle reactor. In this manner, the lighter and smaller components thatmake up the first light material may be separated for consumption orrecycle white the heavy and large components that make up the firstheavy material may be sent to the second nozzle reactor. Sending onlythe first heavy material to the second nozzle reactor may be beneficialbecause the second nozzle reactor will function to specifically crackthese components white not being impeded by the presence of the firstlight material.

Separation of the first light material and the first heavy material mabe accomplished by any suitable means for separation of the components.Properties such as density and boiling point may be used to effectseparation. Separation may include, but is not limited to, separation bydistillation units, gravity separation units, filtration units, andcyclonic separation units.

As with the first light material and the first heavy material, thesecond light material and the second heavy material may also beseparated. Any suitable means for separation, such as those mentionedabove, may be used to effect the separation.

The method may further comprise a step of injecting the first lightmaterial, first heavy material, second light material, or second heavymaterial into the reaction chamber of the first nozzle reactor or secondnozzle reactor. In addition or in place of such a recycle stream, themethod may further comprise a step of injecting the first light materialor second light material into the reaction chamber of the first nozzlereactor.

In some embodiments, a nozzle reactor system includes two or more nozzlereactors aligned in parallel and used for upgrading hydrocarbonmaterial. FIG. 10 illustrates a nozzle reactor system 400 includingthree nozzle reactors 401, 402, and 403 aligned in parallel. The systemalso includes a stream dividing apparatus 410 located upstream of thenozzle reactors 401, 402, 403, and a product mixing apparatus 420located downstream of the nozzle reactors 401, 402, 403. While not shownin FIG. 10, the system can also include a stream heating unit locatedupstream of the nozzle reactors 401, 402, 402. Stream dividing apparatus410 is generally configured to receive a stream of material to beprocessed in the nozzle reactors and divide the stream of material intoone stream or each nozzle reactor in the nozzle reactor system 400. Eachstream produced can be easier to control and measure. As shown in FIG.10, three streams are produced by the stream dividing apparatus 410,with each stream being directed to one of the nozzle reactors 401, 402,403. The product material leaving each of the nozzle reactors 401, 402,403 is then combined in a product mixing apparatus 420. A portion of thecombined product can be recycled back to the stream dividing apparatus410 for further processing in the nozzle reactors 401, 402, 403.

Nozzle reactors 401, 402, 403 may generally include a nozzle reactoraccording to any embodiment or aspect described herein. In someembodiments, nozzle reactors 401, 402, 403 each have a reactor body, aninjection passage, and a material feed passage. The reactor bodyincludes an interior reactor chamber with an injection end and anejection end. The injection passage is mounted in the nozzle reactor inmaterial injecting communication with the injection end of the interiorreactor chamber. Furthermore, the injection passage has an enlargedvolume injection section, an enlarged volume ejection section, and areduced volume mid-section intermediate the enlarged volume injectionsection and enlarged volume ejection section. The injection passage alsohas a material injection end and a material ejection end in injectingcommunication with the interior reactor chamber. The material feedpassage penetrates the reactor body. The location of the material feedpassage is adjacent to the material ejection end of the injectionpassage and transverse to an injection passage axis extending from thematerial injection end to the material ejection end in the injectionpassage.

In some embodiments, nozzle reactors 401, 402, 403 are identical to oneanother in structure and dimension, although nozzle reactors that differin either or both of these characteristics can also be used within thesame nozzle reactor system 400. The operating conditions of each nozzlereactor (e.g., temperature, pressure, etc.) can also be identical ineach nozzle reactor, or the nozzle reactors can operate under differentoperating conditions.

Although only three nozzle reactors are shown in the nozzle reactorsystem 400, the number of nozzle reactors aligned in parallel in thenozzle reactor system 400 is not limited. In some embodiments, theamount of material needing to be upgraded and the relative capacity ofeach nozzle reactor that is part of the system 400 can play a role inthe number of nozzle reactors selected for the system 400.

Stream dividing apparatus 410 generally includes any type of apparatuscapable of dividing a larger stream into numerous smaller streams.Stream dividing apparatus 410 can be adapted to create streams of equalvolumetric flow rates or can create streams having different volumetricflow rates. Stream dividing apparatus 410 can also be adapted to createany desired number of streams, but will generally be set up to createone stream for each nozzle reactor that is a part of the nozzle reactorsystem 400. Exemplary stream dividing apparatus include, hut are notlimited to, flow control valves, limiting orifice valves, orificeplates, flow venturies, pipe tees, pipe manifolds, and baffle plates.

In some embodiments, the stream dividing apparatus 410 can also producestream of varying composition. For example, the stream dividingapparatus 410 can divide a stream of material based on molecular weightor density to produce a stream of material having a high molecularweight or high density, a stream of material having a intermediatemolecular weight or density, and a stream of material having a lowmolecular weight or density. While molecular weight is provided asexample of the criteria on which the material can be divided, any othersuitable criteria can be used for dividing the stream of material,including but not limited to, presence or absence of certain compoundsor class of compounds, boiling point temperatures, and viscosity. Inembodiments where the stream dividing apparatus 410 produces streams ofvarying composition, the stream dividing apparatus 410 can include butis not limited to vacuum or atmospheric distillation towers.

When the stream dividing apparatus 410 produces streams of varyingcomposition, each stream can then be sent to a nozzle reactor in thenozzle reactor system 400 that is specifically tailored for upgradingstreams having a specific composition. Nozzle reactors in the nozzlereactor system 400 can be tailored to upgrade a stream having a specificcomposition by any suitable manner, such as adjusting operatingconditions (e.g., temperature, pressure, etc.) and/or by adjustingvarious dimensions of the nozzle reactor.

Each outlet of the stream dividing apparatus 410 is in fluidcommunication with the feed material injection inlet of one of thenozzle reactors of the nozzle reactor system. In this manner, thematerial leaving the stream dividing apparatus 410 can be injecteddirectly into one of the nozzle reactors 401, 402, 403 for beingsubjected to cracking and upgrading. Any manner of fluid communicationmay be used between the material dividing apparatus 410 and the feedmaterial injection inlets of each nozzle reactors. In one example, thefluid communication may be piping extending between an outlet of thestream dividing apparatus and the material feed injection inlet of eachnozzle reactor.

The material feed fed into the stream dividing apparatus 410 and dividedup into individual streams can include any type of material that may bebroken down into smaller and lighter components. In some embodiments,the material feed is a hydrocarbon source, such as heavy oil, bitumen,crude oil, or any residue with a high asphaltene content. The residuemay be any residual portion of a separated hydrocarbon stream, such asthe bottoms fraction from a distillation unit. The high asphaltenecontent may be an asphaltene content greater than 4 wt % of the residue.Hydrocarbon sources such as these require cracking to break down theheavy and large molecules of the hydrocarbon into light components thatmay be beneficially used. In some embodiments, the material feed ismaterial stream exiting a nozzle reactor located upstream of the nozzlereactors 401, 402, 403 aligned in parallel and part of the nozzlereactor system 400.

The mixing apparatus 420 can include any suitable apparatus forreceiving the material exiting each of the nozzle reactors 401, 402, 403and combining the material back into one stream. In some embodiments,the mixing apparatus 420 generally includes a vessel with multiple inputports for receiving the material leaving each of the nozzle reactors401, 402, 403 in the nozzle reactor system. In some embodiments, themixing apparatus 420 is a Kenics mixer. In such configurations, theejection ends of each nozzle reactor 401, 402, 403 is in fluidcommunication with the input port or ports of the mixing apparatus 420.As described in greater detail above with respect to the connectionbetween the stream dividing apparatus 410 and the nozzle reactors 401,402, 403, the fluid communication between the ejection ends of thenozzle reactors 401, 402, 403 and the injection port or ports of themixing apparatus 420 can be established in any suitable manner,including the use of piping.

The vessel used for the mixing apparatus 420 can optionally includeequipment for mixing the various material streams entering the mixingapparatus 420, such as a mixing blade. The volume of the mixingapparatus 420 should generally be designed such that the mixingapparatus 420 is capable of receiving all of the product materialleaving the nozzle reactors 401, 402, 403 of the nozzle reactor system400. The mixing apparatus 420 can also include an outlet port forallowing combined and optionally mixed material to leave the mixingapparatus 420 and be transported to further processing equipment locateddownstream of the nozzle reactor system 400. In some embodiments, thedownstream processing equipment can serve as the mixing apparatus 420,and thereby both receive each stream leaving the nozzle reactors 401,402, 403, and then subject the combined product streams to furtherprocessing.

In some embodiments, the product streams exiting the nozzle reactors401, 402, 403 are subjected to further processing prior to beingcombined in a mixing apparatus 420. As shown in FIG. 11, processingapparatus 501, 502, 503 are provided for each nozzle reactor 401, 402,403. In such embodiments, the product stream leaving each nozzle reactor401, 402, 403 is sent to a processing apparatus 501, 502, 503. Theproduct streams leaving each process apparatus 501, 502, 503 is thensent to the mixing apparatus 420 described above for combining theproduct streams. A portion of the combined product stream leaving mixingapparatus 420 can be recycled back to the nozzle reactors for furtherprocessing.

Any suitable processing equipment can be used for the processingapparatus 501, 502, 503. In some embodiments, the processing equipmentis equipment capable of further upgrading the product streams leavingthe nozzle reactors 401, 402, 403. In some embodiments, the processingequipment is a coil reactor, such as the coil reactors described in U.S.patent application Ser. No. 12/816,844 and U.S. patent application Ser.No. 13/292,747, both of which are hereby incorporated by reference.

Although FIG. 11 illustrates only one piece of processing equipmentlocated between each nozzle reactor and the mixing apparatus, multiplepieces of processing equipment can be provided per nozzle reactor. Inother words, each product stream leaving nozzle reactors 401, 402, 403,can be subjected to multiple pieces of processing equipment prior tobeing combined in the mixing apparatus 420.

Although not shown in FIG. 10 or 11, the system 400 can further includeseparation apparatus located down stream of the mixing apparatus 420.The separation apparatus can be used to separate the combined streamexiting mixing apparatus 420 into various streams based on any of avariety of criteria. For example, in some embodiments, the combinedstream can be separated based on the boiling points of the variouscomponents included in the combined stream. Any suitable separationapparatus can be used for this step, including, for example,distillation towers.

In some embodiments, a material feed cracking method is disclosed.Methods of the embodiments can generally include a first step ofinjecting a first material stream into a stream dividing apparatus andproducing a first divided stream and a second divided stream. The methodalso includes a step of injecting the first divided stream into a firstnozzle reactor and injecting the second divided stream into a secondnozzle reactor. A next step includes injecting a stream of crackingmaterial into the first nozzle reactor and injecting a stream ofcracking material into the second nozzle reactor. A next step includescombining a first nozzle reactor product from the first nozzle reactorand a second nozzle reactor product from the second nozzle reactor in amixing apparatus.

The stream dividing apparatus, the first nozzle reactor, the secondnozzle reactor, and the mixing apparatus used in the method describedabove can all be similar or identical to the stream dividing apparatus,the nozzle reactor, and the mixing apparatus described in greater detailabove.

The first material stream can include any type of material that may bebroken down into smaller and lighter components. In one aspect of thismethod, the first material stream includes a hydrocarbon source, such asheavy oil, bitumen, crude oil, or any residue with a high asphaltenecontent. The residue may be any residual portion of a separatedhydrocarbon stream, such as the bottoms fraction from a distillationunit. The high asphaltene content may be an asphaltene content greaterthan 4 wt % of the residue. Hydrocarbon sources such as these requirecracking to break down the heavy and large molecules of the hydrocarboninto tight components that may be beneficially used. The first materialstream can also include the material leaving the ejection end of anozzle reactor located upstream of the stream dividing apparatus.

The first divided stream and the second divided stream can be a similaror identical, such as when the stream dividing apparatus performs asimple physical separation of the first material stream. Alternatively,the first divided stream and the second divided stream can havedifferent compositions, such as when the stream dividing apparatus is adistillation tower that separates the first material stream based on theboiling point of the various components of the first material stream.The first divided stream and the second divided stream can also be equalin volumetric flow rate, or can have different volume flow rates. It canalso have a third divided stream with a different volumetric flow rateused as a purge.

The first divided stream and the second divided stream can be injectedinto the first nozzle reactor and the second nozzle reactor,respectively, at any suitable temperature and pressure. In oneembodiment, the first divided stream and the second divided stream areinjected into the first nozzle reactor and the second nozzle reactor ata temperature of from about 300° C. to 500° C. and at a pressure of fromabout 0.5 about to about 15 bar.

The streams of cracking material injected into the first and secondnozzle reactor can be any suitable cracking material for cracking thefirst divided stream and the second divided stream. In some embodiments,the cracking material is a cracking gas, such as steam. The streams ofcracking material can be injected into the nozzle reactors at anysuitable temperature and pressure. In some embodiments, the streams ofcracking material are injected into the nozzle reactors at a temperatureof from about 600° C., to about 850° C., and at a pressure of from about15 bar to about 200 bar.

The pressure inside each of the first and the second nozzle reactor mayrange from about 0.5 bar to about 15 bar. The ratio of cracking materialto material feed may range from about 0.1:1 to about 4:1.

As described in greater detail above, the nozzle reactors operate tocrack and upgrade the feed material injected into the nozzle reactor asa result of the feed material and the cracking material interactingwithin the nozzle reactor. The product of this interaction leaves theejection end of each nozzle reactor as a first nozzle reactor productand a second nozzle reactor product. Each of these stream can betransported to and injected into a mixing apparatus for combining theindividual streams into one larger stream. The operating conditions ofthe mixing apparatus can be adjusted according to the material beinjected into the mixing apparatus. In some embodiments, the temperatureand pressure inside the mixing apparatus will be adjusted. For example,the mixing apparatus can have a temperature in the range of from 350 to420° C. and a pressure in the range of from 0.2 to 15 bar.

Although the above method is described in terms of two nozzle reactors,more than two nozzle reactors can be used. Generally speaking, thestream dividing apparatus will produce one divided stream for eachnozzle reactor that is used in the nozzle reactor system. When thedivided streams have varying compositions, each stream can be directedto a nozzle reactor tailored for upgrading of the specific materialcomposition.

The parallel configurations described above and illustrated in FIGS. 10and 11 can be particularly advantageous in situations where events occurdownstream of the parallel aligned nozzle reactors that requireproduction to be reduced, such as in the event of a pipeline becomingunavailable or a product stream storage facility reaching capacity.Generally speaking, it is undesirable to reduce production by reducingthe flow velocities of the cracking material and the feed material intothe nozzle reactor because such alterations tend to negatively impactthe conversion rate and product quality. The nozzle reactors describedherein provide optimum conversion and product quality when operated atspecific flow velocities for both the cracking material stream and thefeed material stream. In the parallel configuration described herein,production can be reduced by completely shutting down one or more of thenozzle reactors while continuing to operate the remaining on-line nozzlereactors at optimum operating conditions. Thus, the parallel alignmentdescribed herein allows nozzle reactors to continue to operate atoptimum conditions while still providing a mechanism for toweringproduction in the case of downstream events.

Example 1

Cold Lake bitumen is injected into the lower section of a VacuumDistillation Unit (VDU). The bottoms of the VDU are withdrawn from theVDU and comprise a heavy hydrocarbon source having a molecular weightrange of from about 300 Daltons to 5,000 Daltons or more. The heavyhydrocarbon source is pre-heated to a temperature of about 752 deg F.(400 deg C.). At this temperature, only the hydrocarbon fraction with amolecular weight larger then about 350 Dalton will be in the liquidand/or solid phase, white the remainder of the hydrocarbon source is ina gaseous state. The hydrocarbon source is injected into an interiorreactor chamber of a first nozzle reactor via the material feed passageof the first nozzle reactor.

Simultaneously, superheated steam at a temperature of about 1256 deg F.(680 deg C.) is injected into the converging section of the injectionpassage of the first nozzle reactor at a flow rate of about 1.5 timesthe flow rate of the hydrocarbon source.

The first nozzle reactor has an overall length of 8,000 mm and anoutside diameter of 1,600 mm. The interior reactor chamber is 7,160 mmlong with an injection end diameter of 262 mm and an ejection enddiameter of 1,435 mm. The injection passage has a length of 840 mm, withan enlarged volume injection section diameter of 207 mm, a reducedvolume mid-section diameter of 70 mm and an enlarged volume ejectionsection diameter of 147 mm. The pressure in the interior reactor chamberis about 2.

The hydrocarbon source and steam are retained in the first nozzlereactor for a time period of around 1.2 seconds. Shockwaves and thermaleffects produced inside the nozzle convert approximately 45% per pass ofthe hydrocarbon source that has a boiling point of greater than 1050 degF. (566 deg C.) into lighter hydrocarbons with a boiling point of lessthan 1050 deg F. (566 deg C.). The nozzle reactor emits a mixture ofsteam, cracked hydrocarbons, and uncracked hydrocarbons at a temperatureof about 788 deg F. (420 deg C.).

The mixture leaving the nozzle reactor is recycled to the same VDU asnoted before. Steam in the VDU is condensed. The VDU separates thehydrocarbon into a gaseous hydrocarbon phase (C5 and smaller), gas oil,vacuum distillate and VDU bottoms having a molecular weight range offrom 300 Daltons to 5,000 Daltons or more. The gaseous hydrocarbonphase, gas oil and vacuum distillate are collected for consumption. TheVDU bottoms are split into two individual streams. A first streamcomprising about 75% of the total VDU bottoms stream is recycled back tothe first nozzle reactor, while a second stream comprising the remaining25% is diverted to a second nozzle reactor. This split purges a fractionof the bottoms that has an increased amount of inorganic material, suchas vanadium, nickel, and sulfur.

Prior to being introduced into the second nozzle reactor, the secondstream is cooled to a temperature of about 700 deg F. (371 deg C.). Atthis temperature, all of the hydrocarbon material of the second streamis in the liquid phase. The second stream is injected into an interiorreactor chamber of a second nozzle reactor via the material feed passageof the second nozzle reactor. Simultaneously, steam at a temperature of1256 deg F. (680 deg C.) is injected into the interior reactor chamberof the second nozzle reactor via the injection passage at a flow rate ofabout 2.0 times the flow rate of the hydrocarbon injected into thesecond nozzle reactor.

The second nozzle reactor has an overall length of 7,000 mm and anoutside diameter of 1,300 mm. The interior reactor chamber is 6,400 mmlong with an injection end diameter of 187 mm and an ejection enddiameter of 1,231 mm. The injection passage has a length of 600 mm, withan enlarged volume injection section diameter of 148 mm, a reducedvolume mid-section diameter of 50 mm and an enlarged volume ejectionsection diameter of 105 mm. The pressure in the interior reactor chamberis about 2.

The second stream and steam are injected into the second nozzle reactorfor a time period of no more than 0.6 seconds. Shockwaves producedinside the nozzle reactor convert approximately 55% of the second streaminto lighter hydrocarbons. The nozzle reactor emits a mixture of steam,cracked hydrocarbons and untracked hydrocarbons at a temperature ofabout 788 deg F.

The mixture leaving the second nozzle reactor is fed to a small VacuumSeparation Unit (VSU). The small VSU separates the mixture into alighter hydrocarbon having a molecular weight in the range of from about25 to about 200 Daltons and a heavier hydrocarbon stream having amolecular weight in the range of from about 200 to about 1,000 Daltons.The light hydrocarbon stream is recycled back to the first and large VSUwhile the heavier hydrocarbon stream is cooled down to about 700 deg F.(371 deg C.) and collected as the final pitch stream for disposal.

In view of the many possible embodiments to which the principles of thedisclosed invention may be applied, it should be recognized that theillustrated embodiments are only preferred examples of the invention andshould not be taken as limiting the scope of the invention. Rather, thescope of the invention is defined by the following claims. We thereforeclaim as our invention all that comes within the scope and spirit ofthese claims.

What is claimed is:
 1. A nozzle reactor system comprising: a streamdividing apparatus comprising a first output port and a second outputport; a first nozzle reactor having a feed material injection port influid communication with the first output port of the stream dividingapparatus, and an ejection end; a second nozzle reactor having a feedmaterial injection port in fluid communication with the second outputport of the stream dividing apparatus, and an ejection end; and a mixingapparatus having a first input port in fluid communication with theejection end of the first nozzle reactor, and a second input port influid communication with the ejection end of the second nozzle reactor.2. The nozzle reactor system as recited in claim 1, wherein: the firstnozzle reactor comprising in combination: a reactor body having aninterior reactor chamber with an injection end and an ejection end; aninjection passage mounted in the nozzle reactor in material injectingcommunication with the interior reactor chamber, the injection passagehaving (a) an enlarged volume injection section, an enlarged volumeejection section, and a reduced volume mid-section intermediate theenlarged volume injection section and enlarged volume ejection section,(b) a material injection end, and (c) a material ejection end ininjecting communication with the interior reactor chamber; a materialfeed passage penetrating the reactor body and being (a) adjacent to thematerial ejection end of the injection passage and (b) transverse to aninjection passage axis extending from the material injection end to thematerial ejection end in the injection passage; and the second nozzlereactor comprising in combination: a reactor body having an interiorreactor chamber with an injection end and an ejection end; an injectionpassage mounted in the nozzle reactor in material injectingcommunication with the interior reactor chamber, the injection passagehaving (a) an enlarged volume injection section, an enlarged volumeejection section, and a reduced volume mid-section intermediate theenlarged volume injection section and enlarged volume ejection section,(b) a material injection end, and (c) a material ejection end ininjecting communication with the interior reactor chamber; a materialfeed passage penetrating the reactor body and being (a) adjacent to thematerial ejection end of the injection passage and (b) transverse to aninjection passage axis extending from the material injection end to thematerial ejection end in the injection passage; and
 3. The nozzlereactor system as claimed in claim 2, wherein the enlarged volumeinjection section of each of the first and second nozzle reactorsincludes a converging central passage section, and the reduced volumemid-section and the enlarged volume ejection section of each of thefirst and second nozzle reactors includes a diverging central passagesection.
 4. The nozzle reactor system as claimed in claim 3, wherein theconverging central passage section, the reduced volume mid-section, andthe diverging central passage section of each of the first and secondnozzle reactors provide a radially inwardly curved passage side wallintermediate the material injection end and material ejection end in theinjection passage of each of the first and second nozzle reactors. 5.The nozzle reactor system as claimed in claim 2, wherein (a) theinterior reactor chamber of each of the first and second nozzle reactorshas a central interior reactor chamber axis extending from the injectionend to the ejection end of the interior reactor chamber and (b) aninjection passage axis of each of the first and second nozzle reactorsis coaxial with the central interior reactor chamber axis of each of thefirst and second nozzle reactors.
 6. The nozzle reactor system asclaimed in claim 2, wherein the enlarged volume injection section,reduced volume mid-section, and enlarged volume ejection section in theinjection passage of each of the first and second nozzle reactorscooperatively provide a substantially isentropic passage for a crackingmaterial through the injection passage of each of the first and secondnozzle reactors.
 7. The nozzle reactor system as claimed in claim 2,wherein the material feed passage of each of the first and second nozzlereactors is annular.
 8. The nozzle reactor system as claimed in claim 2,wherein the interior reactor chamber of each of the first and secondnozzle reactors includes a cross-sectional area and wherein thecross-sectional area alternates between maintaining constant andincreasing in a direction from the injection end to the ejection end. 9.The nozzle reactor system as claimed in claim 1, wherein the streamdividing apparatus comprises a distillation tower.
 10. The nozzlereactor system as claimed in claim 1, further comprising: an upstreamnozzle reactor located upstream of the stream dividing apparatus andwherein an ejection of the upstream nozzle reactor is in fluidcommunication with an input port of the stream dividing apparatus.
 11. Amaterial cracking method comprising: injecting a first material streaminto a stream dividing apparatus and producing a first divided streamand a second divided stream; injecting the first divided stream into afirst nozzle reactor and injecting the second divided stream into asecond nozzle reactor; injecting a stream of cracking material into thefirst nozzle reactor and injecting a stream of cracking material intothe second nozzle reactor; and combining a first nozzle reactor productfrom the first nozzle reactor and a second nozzle reactor product fromthe second nozzle reactor in a mixing apparatus.
 12. The materialcracking method as claimed in claim 11, wherein the first divided streamand the second divided stream are injected into the first and secondnozzle reactor at a direction transverse to the direction the crackingmaterial is injected into the first and second nozzle reactor.
 13. Thematerial cracking method as claimed in claim 11, wherein the crackingmaterial is steam.
 14. The material cracking method as claimed in claim11, wherein the first material stream hydrocarbon material.
 15. Thematerial cracking method as claimed in claim 14, wherein the hydrocarbonmaterial comprises bitumen.
 16. The material cracking method as claimedin claim 11, wherein the first divided stream has a differentcomposition from the second divided stream.
 17. The material crackingmethod as claimed in claim 11, wherein the first material streamcomprises material collected from the ejection end of an upstream nozzlereactor.